Fire retardant insulated modular building panels

ABSTRACT

A fire retardant, weight-bearing building panel having a frame enclosing fiberglass insulating material which is press-fitted between a pair of aluminum-plywood bonded sheet faces. The plywood is treated with a solution to render it substantially non-combustible. Added fire resistance is obtained by including one or two sheets of gypsum board between the outer wood sheets.

[ Sept. 3, 1974 1 1 FIRE RETARDANT INSULATED MODULAR BUILDING PANELS[75] Inventor: Henry G. Hiatt, Edgewater, Md.

1731 Assignee: Annapolis Yacht Yard, Inca,

Annapolis, Md.

1221 Filed: June 6, 1972 1211 Appl. No.: 260,195

. 152] US. Cl 52/127, 52/469, 52/580, 52/573 [51] Int. Cl E04b 1/343,E04b 1/41 {58] Field of Search 52/404413, 52/456-458, 612629, 580, 586,582, 755, 766, 127, 469, 232, 756, 573; 117/132 BC [56] References CitedUNITED STATES PATENTS 948,450 2/1910 Hussey 52/404 1,187,545 6/1916Olberg 52/405 2,054,694 9/1936 Eldredge... 52/615 2,233,711 3/1941Pasquier 52/615 2,582,467 1/1952 Sylvan 52/623 2,593,050 4/1952 Paul eta1 1, 52/615 3,160.515 12/1964 Goldstein et 117/136 3,194,777 7/1965Christenson et a1, 117/132 3,217,455 11/1965 Burges 1 52/404 3,235,0402/1966 Ellis 52/623v 3,273,297 9/1966 Wehe 1 1 52/404 3,285,774 11/1966(ioldstcin et all, 117/136 3,364,645 1/1968 wenzelbergcrn. 52/6153,711,313 1/1973 Nagano et ul. 117/1321! Primary lixaminer]ohn E.Murtagh Assistant Examiner-.1ames L. Ridgill, Jr. Attorney, Agent, orFirm-Arthur Schwartz 5 7 ABSTRACT A fire retardant, weight-bearingbuilding panel having a frame enclosing fiberglass insulating materialwhich is press-fitted between a pair of aluminum-plywood bonded sheetfaces. The plywood is treated with a solution to render it substantiallynon-combustible. Added fire resistance is obtained by including one ortwo sheets of gypsum board between the outer wood sheets.

9 Claims, 7 Drawing Figures FIRE RETARDANT INSULATED MODULAR BUILDINGPANELS BACKGROUND OF THE INVENTION 1. Field of the Invention Theinvention relates to fire resistant, weight-bearing panels which aredesigned for use in cold storage structures. More specifically, thepanels are built in modular form to be incorporated in cold storagebuildings adapted to house refrigerated foods.

Cold storage rooms and buildings must be able to not only provide thenecessary insulation to keep the food cold, but must also be able tomeet certain fire hazard classifications. For example, a recognizedauthority in material and product testing for public safety is theUnderwriters Laboratory, Inc. Within their fire hazard classificationthey have established minimum standards in three categories for testingbuilding materials. The classification includes the following areas:

Flame Spread how fast the flame will spread over the length of thematerial which is placed in a furnace specifically designed for suchtests. An acceptable rating is 25.

Fuel Contribution an indication of how much the material in the furnacecontributes to the fuel; Having a known Btu input, the output ismeasured, and the difference is the fuel contribution. An acceptablerating in this area is also 25.

Smoke Developed a measure of the smoke coming out of the chimney as aresult of the test material being burnt. Again, 25 is an acceptablerating.

Finally, there is a rating given relative to the time it takes for awall panel to burn completely through. An acceptable classification incertain instances may be a 30-minute wall, while in others it isdesirable to have a 1-hour or a 2-hour wall. While the wall panel isbeing exposed to the fire, it will be required to support the equivalentto a 60 pounds per square foot roof loading.

Therefore, in designing a weight-bearing wall panel it is necessary totake into consideration the length of time it takes the panel to burncompletely through while supporting an equivalent roof load of 60 poundsper square foot, the flame spread, fuel contributed and smoke developed.

2. Description of Prior Art On a commercial scale the most widely usedmodular panels include foamed plastic material as the primary source ofinsulation. While such panels may have an acceptable Flame Spread ratingof, for example 25, they have a distinct disadvantage in that themelting point of foam is about 150 to 250 F. This has provided in sometests a Smoke Developed rating of over 500. The smoke is black and toxicso fire-fighters are often unable to find the exact location of thefire. Also, whereas there may be only superficial damage to the exteriorof the building structure, the actual damage may be in the order ofhundreds or thousands of times worse because the entire foam interior ofthe building may have melted.

SUMMARY OF THE INVENTION In accordance with the instant invention, theshortcomings and disadvantages of the prior art have been alleviated bythe unique combination of materials to provide a fire retardant panelhaving the desired fire resistance test capability, as well asappropriate fire hazard classifications. Set out below will be threetypes of panels which have nominal ratings of 30 minutes, 1 hour and 2hours, respectively. The panels designed by Applicant have a fire hazardclassification as follows:

Flame Spread 25 Fuel Contributed 10 Smoke Developed 0 As will be seenfrom the discussion below and when compared to the prior art, Applicantspanel has the same fire resistance time test, comparable Flame Spreadand Fuel Contribution, but developed no smoke when exposed to heat andfire.

The first embodiment of the invention may be considered as nominally a,30-minute wall having an interior face of plywood with an aluminum orbaked reflective acrylic metal surface bonded thereto. Thealuminum-plywood face is attached to a wood frame having fiberglassinsulation press-fitted therein. To the other side of the frame isattached a second aluminumplywood bonded face.

A SO-minute roofing panel is constructed in a similar manner.

A second embodiment of the 30-rninute wall is in the form of at least aone-hour wall which has one sheet of gypsum board running through thecenter of the fiberglass.

A third embodiment designed to be rated as at least a 2-hour wallincludes gypsum board positioned between each plywood face and the innersection of fiberglass.

As will be seen in the detailed discussion of the various embodimentsbelow, the instant invention combines the properties of each of thecomponents to provide a compact panel member which is not only effectiveas a thermal insulating panel, but also provides the necessary fireresistance and weight-bearing capability to make it superior to theknown prior art.

BRIEF DESCRIPTION OF THE DRAWINGS Further advantages of the inventionwill become apparent from the detailed description below when taken withthe accompanying drawings which illustrate, by way of examples, severalembodiments of the invention wherein:

FIG. 1 is a plan view of a wall panel of the present invention;

FIG. 2 is an enlarged fragmentary transverse sectional view, taken alongline 2-2 of FIG. 1;

FIG. 3 is an enlarged vertical sectional view, taken along line 33 ofFIG. 1;

FIG. 4 is a vertical section view similar to FIG. 3 of a modified formof the wall panel;

FIG. 5 is an enlarged fragmentary vertical sectional view, taken alongline 5-5 of FIG. 4;

FIG. 6 is a vertical sectional view of still another modification of thewall panel; and

FIG. 7 is an enlarged fragmentary vertical sectional view taken alongline 7-7 of FIG. 6.

DETAILED DESCRIPTION OF THE INVENTION FIG. 1 illustrates three modularpanels ll, 3 and 5 connected together by a plurality of lag and podarrangements 7. As seen in FIGS. 2 and 3 the sections have an exteriorface 9 and an interior face 11. The exterior face 9 is composed of aplywood layer 13 having a natural aluminum or a baked reflective acrylicmetal surface 15 bonded thereto. The aluminum bonded metal surface iseasily cleaned, always stays sanitary (U.S.D.A. approved) and positivelyreflects sun rays.

The plywood face which is about one-quarter inch thick is treated with afire-retardant chemical such described as in US. Pat. Nos. 3,160,515 or3,285,774 or that sold under the trademark name of Non-Com Exterior byKoppers Company, Inc. The salt solution used for treating the plywood ispressure impregnated into the wood in autoclaves capable of withstandingpressure of up to 200 pounds per square inch. After impregnation, theplywood is processed in a kiln where the chemicals of impregnation arecured. The curing sets the chemicals in the wood cells and impartsdurable weather-resisting fire retardance. The plywood so treated itselfhas an Underwriters Laboratory fire hazard classification of 25 or lessfor Flame Spread, Fuel Contributed and Smoke Developed, and shows nosign of progressive combustion when the fire hazard classification testis continued for minutes. This rating applies regardless of theexposure. This particular treatment will not leech out and has nosignificant change in performance after exposure to weather andmoisture.

A plurality of plastic access hole covers 17 may be placed atappropriate intervals along the interior face for the purpose ofcovering holes cut in the face 11 for providing access to lag and podconnectors 7.

Framing means have a pair of end rails 19 and a pair of side rails 21positioned between the interior and exterior faces 9 and 11. The framingmembers also include a plurality of interior bracing sections 23. Theinterior bracing sections are separated from one another by a space 25to prevent heat conduction through modular panel. An oversized batt formof fiberglass insulation 27 (for example, RA-25, Owens-Corning) ispressfitted in each of the sections between the interior and exteriorfaces. The plywood faces are secured to the framing members by means ofa plastic resin glue 28 around the perimeter of the framing. Staples 29are used along the perimeter to further secure the faces to the framingmembers. The fiberglass insulating material 27 is pressed into spaces25.

A mastic sealing caulking tape with aluminum trim 31 is seen in FIGS. 1,2, 5 and 7 covering the area adjoining the panels.

A quarter-inch felt joint 33 to serve as an expansion joint ispositioned between the joined side panels 21. The joint is composed oftwo one-eighth inch wool felt gaskets treated against fungus and wateron each side panel and permits expansion and contraction counteractingeffects of rapid temperature change. This is seen in greater detail inFIGS. 5 and 7 which will be discussed in greater detail below with therespective modifications.

The embodiment illustrated in FIGS. 4 and 5 is identical with that shownin FIGS. 1-3 except that a fiveeighth inch fire rated gypsum wall board35 is positioned between the joint members 23 in space 25. This singlegypsum board will add at least an extra half-hour to the wall rating,thus providing at least a 1-hour rated wall, i.e., it will take an hourto burn through the entire wall panel under certain specified testconditions. The fiberglass is positioned in two sections 27 on each sideof the gypsum board 35.

The embodiment illustrated in FIGS. 6 and 7 illustrates a 2-hour ratedfire wall and is the same as the embodiments of FIGS. 1-3 except that itincludes a pair of five-eighth inch fire-rated gypsum wallboards 37nailed to the spreaders before securing the interior and exterioraluminum bonded plywood faces. This particular structure will give atleast a 2-hour rated wall.

A roofing panel has been designed in substantially the same manner asthe wall panel. The primary difference is that the exterior face isone-half inch plywood as opposed to one-quarter inch plywood in the wallpanels.

While there has been described and illustrated specific embodiments ofthe invention, it will be clear that variations in the details of theembodiments specifically illustrated and described may be made withoutdeparting from the true spirit and scope of the invention as defined inthe appended claims.

What is claimed is:

l. A fire retardant insulated building wall comprising:

a. a plurality of modular panels each including:

1. framing means for supporting a plurality of sheet materials; 2.fiberglass insulating material within said framing means; 3. plywoodsheets positioned transversely on each side of said framing means forfully enclosing said fiberglass material adjacent the interior surfacesthereof, said plywood sheets being treated with a solution for renderingthem substantially noncombustible; 4. metal bonded to the exteriorsurface of said plywood sheets; and 5. at least one pair of interiorbracing sections separated from one another to prevent heat conductionthrough the modular panel; b. said plurality of panels being securedtogether by attaching means, and covered access openings on at least oneside of the panel to provide access to the attaching means joining saidpanels together; and c. expansion materials between adjacent panels anda sealing trim material over the line of juncture. 2. A fire retardantinsulated building panel as defined in claim 1 wherein a building panelis provided having an Underwriters Laboratory classification of about 25or less for Flame Spread, Fuel Contribution, and Smoke Developed.

3. A fire retardant insulated building panel as defined in claim 2wherein said classification is about as follows:

Flame Spread 25 Fuel Contributed 10 Smoke Developed 0.

4. A fire retardant insulated building panel as defined in claim 1including at least one sheet of additional fire resistant materialbetween said wood sheets.

5. A fire retardant insulated building panel as defined in claim 4wherein said fire resistant material is gypsum board.

6. A fire retardant insulated building panel as defined in claim 4wherein a sheet of said fire resistant material is positionedapproximately midway between said wood sheets.

6 7. A fire retardant insulated building panel as defined aluminumtherein. in claim 4 wherein a sheet of said fire resistant material 9. Afire retardant insulated building panel as defined is positionedadjacent each of said wood sheets. in claim 1 wherein said metal sheetshave a baked re- 8. A fire retardant insulated building panel as definedflective acrylic metal surface. in claim 1 wherein said metal sheets atleast include 5

1. A fire retardant insulated building wall comprising: a. a pluralityof modular panels each including:
 1. framing means for supporting aplurality of sheet materials;
 2. fiberglass insulating material withinsaid framing means;
 3. plywood sheets positioned transversely on eachside of said framing means for fully enclosing said fiberglass materialadjacent the interior surfaces thereof, said plywood sheets beingtreated with a solution for rendering them substantiallynon-combustible;
 4. metal bonded to the exterior surface of said plywoodsheets; and
 5. at least one pair of interior bracing sections separatedfrom one another to prevent heat conduction through the modular panel;b. said plurality of panels being secured together by attaching means,and covered access openings on at least one side of the panel to provideaccess to the attaching means joining said panels together; and c.expansion materials between adjacent panels and a sealing trim materialover the line of juncture.
 2. fiberglass insulating material within saidframing means;
 2. A fire retardant insulated building panel as definedin claim 1 wherein a building panel is provided having an Underwriter''sLaboratory classification of about 25 or less for Flame Spread, FuelContribution, and Smoke Developed.
 3. plywood sheets positionedtransversely on each side of said framing means for fully enclosing saidfiberglass material adjacent the interior surfaces thereof, said plywoodsheets being treated with a solution for rendering them substantiallynon-combustible;
 3. A fire retardant insulated building panel as definedin claim 2 wherein said classification is about as follows:
 4. metalbonded to the exterior surface of said plywood sheets; and
 4. A fireretardant insulated building panel as defined in claim 1 including atleast one sheet of additional fire resistant material between said woodsheets.
 5. A fire retardant insulated building panel as defined in claim4 wherein said fire resistant material is gypsum board.
 5. at least onepair of interior bracing sections separated from one another to preventheat conduction through the modular panel; b. said plurality of panelsbeing secured together by attaching means, and covered access openingson at least one side of the panel to provide access to the attachingmeans joining said panels together; and c. expansion materials betweenadjacent panels and a sealing trim material over the line of juncture.6. A fire retardant insulated building panel as defined in claim 4wherein a sheet of said fire resistant material is positionedapproximately midway between said wood sheets.
 7. A fire retardantinsulated building panel as defined in claim 4 wherein a sheet of saidfire resistant material is positioned adjacent each of said wood sheets.8. A fire retardant insulated building panel as defined in claim 1wherein said metal sheets at least include aluminum therein.
 9. A fireretardant insulated building panel as defined in claim 1 wherein saidmetal sheets have a baked reflective acrylic metal surface.